Wedge and plug tooling for pre-carbonization compression of oxidized pan fiber preform

Abstract

A shape forming tool for pre-carbonization compression of a fibrous preform is provided, comprising a female forming tool, a first plug, a second plug, and a wedge, each configured to be received by a die recess of the female forming tool. A first tapered surface of the wedge is configured to engage the first plug and the second tapered surface of the wedge is configured to engage the second plug. In response to the first tapered surface of the wedge engaging the first plug and the second tapered surface of the wedge engaging the second plug, the first plug and the second plug, respectively, are configured to move laterally towards opposing sides of the female forming tool and/or vertically toward a bottom side of the female forming tool to compress the fibrous preform into a shaped body.

1 . A shape forming tool, comprising:
 a female forming tool comprising a die recess, the female forming tool extends longitudinally along a longitudinal centerline of the female forming tool between and to a first end of the female forming tool and a second end of the female forming tool, and the female forming tool extends laterally between and to a first side of the female forming tool and a second side of the female forming tool;   a first plug configured to be received by the die recess;   a second plug configured to be received by the die recess;   a wedge configured to be received by the die recess between the first plug and the second plug, the wedge extends longitudinally along a longitudinal centerline of the wedge between and to a first end of the wedge and a second end of the wedge, the wedge extends laterally between and to a first side of the wedge and a second side of the wedge, the first side of the wedge comprises a first tapered surface and the second side of the wedge comprises a second tapered surface;   wherein the first tapered surface of the wedge is configured to engage the first plug and the second tapered surface of the wedge is configured to engage the second plug;   in response to the first tapered surface of the wedge engaging the first plug, the first plug is configured to move laterally toward the first side of the female forming tool; and   in response to the second tapered surface of the wedge engaging the second plug, the second plug is configured to move laterally toward the second side of the female forming tool.   
     
     
         2 . The shape forming tool of  claim 1 , wherein the female forming tool extends vertically between and to a bottom side of the female forming tool and a top side of the female forming tool; and
 wherein the die recess extends vertically into the female forming tool from a first top surface and a second top surface of the female forming tool to a recess surface of the female forming tool, wherein the first top surface and the second top surface are arranged on opposing sides of the recess surface at the top side of the female forming tool;   wherein the die recess extends longitudinally in the female forming tool between and to the first end of the female forming tool and the second end of the female forming tool;   the die recess extends laterally in the female forming tool between the first side of the female forming tool and the second side of the female forming tool; and   
       the die recess is configured without any sharp corners or sharp transitions. 
     
     
         3 . The shape forming tool of  claim 1 , wherein the die recess extends into the female forming tool from a first top surface and a second top surface of the female forming tool to a recess surface of the female forming tool, wherein the recess surface comprises a radii surface forming a rounded, convex surface transition disposed between a sidewall portion of the recess surface and the first top surface of the female forming tool. 
     
     
         4 . The shape forming tool of  claim 1 , further comprising a caul plate configured to be disposed between the fibrous preform and at least one of the wedge, the first plug, and the second plug, wherein the caul plate is configured to distribute a force between the at least one of the wedge, the first plug, and the second plug and the fibrous preform during a pre-carbonization compression process. 
     
     
         5 . The shape forming tool of  claim 1 , wherein the first plug comprises a first angled surface configured to engage the first tapered surface of the wedge, and the second plug comprises a second angled surface configured to engage the second tapered surface of the wedge. 
     
     
         6 . The shape forming tool of  claim 5 , wherein the first tapered surface comprises a guide flange protruding therefrom, and the first angled surface comprises a guide slot configured to receive the guide flange for maintaining a longitudinal position and a rotational position of the first plug with respect to the wedge. 
     
     
         7 . The shape forming tool of  claim 6 , wherein the guide flange is disposed entirely within a laterally outermost boundary of the wedge. 
     
     
         8 . The shape forming tool of  claim 1 , wherein at least one of the wedge, the first plug, or the second plug comprises a threaded aperture at top side thereof for receiving a lifting apparatus whereby at least one of the wedge, the first plug, or the second plug is moved. 
     
     
         9 . A shape forming tool, comprising:
 a female forming tool comprising a die recess;   a first plug configured to be received by the die recess;   a second plug configured to be received by the die recess;   a wedge configured to be received by the die recess between the first plug and the second plug, the wedge extends longitudinally along a longitudinal centerline of the wedge between and to a first end of the wedge and a second end of the wedge, the wedge extends laterally between and to a first side of the wedge and a second side of the wedge, the first side of the wedge comprises a first tapered surface and the second side of the wedge comprises a second tapered surface;   wherein the first tapered surface of the wedge is configured to engage the first plug and the second tapered surface of the wedge is configured to engage the second plug;   in response to the first tapered surface of the wedge engaging the first plug, the first plug is configured to move vertically toward a bottom side of the female forming tool; and   in response to the second tapered surface of the wedge engaging the second plug, the second plug is configured to move vertically toward the bottom side of the female forming tool.   
     
     
         10 . The shape forming tool of  claim 9 , wherein:
 in response to the first tapered surface of the wedge engaging the first plug, the first plug is configured to move laterally toward a first side of the female forming tool; and   in response to the second tapered surface of the wedge engaging the second plug, the second plug is configured to move laterally toward a second side of the female forming tool.   
     
     
         11 . The shape forming tool of  claim 10 , wherein a total height of the wedge, measured along a vertical direction, is equal to that of the first plug and the second plug. 
     
     
         12 . A method for manufacturing a C/C part, the method comprising:
 positioning an oxidized PAN fiber preform with a female forming tool, the female forming tool comprising a die recess;   forming the oxidized PAN fiber preform into a shaped body, the forming comprising:
 moving a first plug at least partially into the die recess, the oxidized PAN fiber preform disposed between the first plug and the female forming tool; 
 moving a second plug at least partially into the die recess, the oxidized PAN fiber preform disposed between the second plug and the female forming tool; 
 moving a wedge between and against the first plug and the second plug along a first axis; 
 in response to the wedge pressing between and against the first plug and the second plug, moving the first plug and the second plug along a second axis substantially perpendicular to the first axis; 
 in response to moving the first plug and the second plug along the second axis, compressing the oxidized PAN fiber preform between the first plug and the female forming tool and between the second plug and the female forming tool. 
   
     
     
         13 . The method of  claim 12 , wherein movement of the wedge along the first axis further causes the first plug and the second plug to move parallel to the first axis. 
     
     
         14 . The method of  claim 13 , further comprising, in response to the wedge moving along the first axis, compressing the oxidized PAN fiber preform between the wedge and the female forming tool. 
     
     
         15 . The method of  claim 13 , wherein the first plug and the second plug are in direct contact with the oxidized PAN fiber preform when the wedge is pressed between and against the first plug and the second plug. 
     
     
         16 . The method of  claim 12 , further comprising gripping the oxidized PAN fiber preform with a gripper plate, wherein a lateral end of the oxidized PAN fiber preform is held between the gripper plate and a clamping surface of the female forming tool. 
     
     
         17 . The method of  claim 16 , wherein a first layer of the oxidized PAN fiber preform is held by the gripper plate and a second layer of the oxidized PAN fiber preform is slidable against the clamping surface of the female forming tool. 
     
     
         18 . The method of  claim 12 , further comprising applying water to the oxidized PAN fiber preform prior to the oxidized PAN fiber preform being formed into the shaped body. 
     
     
         19 . The method of  claim 12 , further comprising applying heat to the oxidized PAN fiber preform for a predetermined duration while the oxidized PAN fiber preform is held in compression in the die recess. 
     
     
         20 . The method of  claim 12 , further comprising:
 moving the shaped body into a graphite fixture;   performing a carbonization process on the shaped body; and   depositing carbon on and within the shaped body via a chemical vapor infiltration process while the shaped body is secured in the graphite fixture.